Molded, resin impregnated fibrous rigid product



y 1968 M. J. GLUCK 3,383,272

MOLDED, RESIN IMPREGNATED FIBROUS RIGID PRODUCT Original Filed Jan. 28, 1961 VIIIIIIIIIII IIJ INVENTOR.

WW WW ATTORNEYS United States Patent 3,383,272 MOLDED, RESIN IMPREGNATED FIBROUS RIGID PRODUCT Martin J. Gluck, Somerset, Mass, assignor, by mesne assignments, to The General Fireproofing Company, Youngstown, Ohio, a corporation of Chic Original application July 28, 1961, Ser. No. 127,569, now Patent No. 3,121,656, dated Feb. 18, 1964. Divided and this application Sept. 19, 1963, Ser. No. 309,972

6 Claims. (Cl. 16144) This application is a division of United States patent application Ser. No. 127,569, filed July 28, 1961 when has now issued as US. Patent No. 3,121,656 dated Feb. 18, 1964. a

The present invention relates to an improved composition of material adapted to be molded into complex contoured and deep-drawn products, a process for forming deep-drawn products of such material and an improved molded product.

Heretofore a number of compositions have been developed in the form of resin-impregnated fibers for use in molding products such as luggage, furniture, construction and building panels, automotive parts, etc. These compositions have included a highly compacted fibrous web with a filter material. Such composition, however, must be pre-shaped and conformed to the shape of the mold before being placed in it in order to permit a proper closing. Material has also been made which comprises inert staple fibers needled into an interlocked body and heavily impregnated with a tacky film-forming or plasticized resin such as phenol formaldehyde to form a mass without voids or pores. When such compositions are molded particularly in deep-draw molds, the heavily compacted fiber mass will tear or wrinkle particularly in the contoured portions. Moreover, such composition often has unimpregnated portions which result in a nonuniform molded product. Materials impregnated with resins such as phenol formaldehyde, in addition to being difficult to mold due to restriction of fiber movement and lack of uniform impregnation, are difiicult to store safely prior to molding. These materials very often tend to set during storage. They also require long cure cycles and in many instances leave objectionable odors in the finished product.

It is therefore an object of the present invention to provide a heat moldable composition particularly useful in forming deep-drawn contoured products. The composition may be molded without pre-forming, shaping or trimming prior Ito insertion in a mold with the final prodnot having a nonwrinkled surface and uniform thickness.

A further object of the present invention is to provide a composition for deep-draw molding which is easily shaped due to the freedom of movement of individual fibers relative to one another. The composition is also designed to provide an end product having greater compactness and consequently greater strength in contoured portions than in fiat portions.

Furthermore this composition has unlimited stability in its pre-mclded form. The composition does not contain odor bearing plasticizers (and consequently is odor free. Moreover the composition is relatively inexpensive and readily moldable.

In the present invention there is provided a composition comprising a plurality of fibers intertwined to form a porous mechanically interlocked fibrous mass. The mass of fibers are preferably formed of jute needled o-r gigged into an interlocked porous mass. Dispersed throughout the mass are discrete particles preferably in a particle size of between .01 micron. and .55 micron, of nontacky, nonfilm. forming, nonplasticized heat moldable resin, preferably a polyvinyl chloride resin having a molecular 3,383,272 Patented May 14, 1968 weight ranging preferably between about 60,000 and 150,000. The resin particles and fibers comprise a nondisplaceable bulk with voids formed therein in la fiber and resin to void ratio of between. 1 to 3 and 1 to 32. The resin preferably comprises one-half of the weight of the fibers but may range by weight between 2% and of the total weight of the resin and fibers depending on the nature of the fiber. The bulkier the fiber, the greater the weight of the resin. This composition may be readily fitted into deep draw molds and compacted and molded under heat and pressure without the necessity of preforming, shaping, trimming or cutting. Nor is there normally any need for further impregnation of the composition or for surface finishing after molding. The composition when positioned in a deep draw mold will readily conform to the shape of the mold without tearing or shearing in portions. The finished product will have a uniform thickness conforming to the desired shape as defined by the mold with portions in the contoured parts more heavily compacted than other portions. This is normally desirable as the curved portions are usually the weakest parts of the molded product, and require the greatest amount of reinforcement.

The present invention also provides a novel means for forming a molded product wherein a chemically inert porous fibrous mass, preferably jute fibers, is impregnated with a quantity of discrete nonfilm formin nonplasticize'd, nontacky heat moldable particles, preferably polyvinyl chloride particles, with these particles dispersed by means of an aqueous volatile vehicle throughout the mechanically interlocked porous mass. The particles are homogeneously infiltrated throughout the mass, and in the case of jute fibers also penetrate the hollow cellulose structure of the fibers. This impregnated mass, preferably after drying, may be formed into a deep-drawn shape by introducing the composition into a mold and thereafter applying heat and pressure to com-pact the fibers into a dense relatively rigid structure.

While the foregoing suggests the preferred embodiments of the invention, also contemplated is a composition formed of pre-treated fibers wherein the fibers are individually coated with film-forming or non-film forming resins of the thermoplastic or thermosetting type or combination thereof. These fibers are formed in a mass and interlocked by needling or gigging with a preselected ratio of voids to solids which permit the mass to be readily formed into a contoured shape and thereafter compacted into a relatively rigid form under the influence of heat and pressure.

These and other objects and advantages of the present invention will be more clearly understood when considered in conjunction with the accompanying drawings, in which:

FIGS. 1 to 5 are schematic illustrations of steps in the process of forming a molded product; and

FIG. 6 is a schematic illustration of an impregnated composition com-prising the present invention.

Referring to FIG. 6 there is illustrated a flexible, deformable, compressible, chemically stable, light-weight, moldable mass. This mass comprises a web of fibers 10 which may be in staple or sliver form. These fibers are interlocked into a porous mass by suitable mechanical means such as conventional needling or gigging wherein small groups of tufts of fibers are pulled through the web, usually by barbed needles, to interlock the fibers of the Web into an integral mass. The fibers are preferably hollow cellular jute fibres but may comprise other inert natural or synthetic fibers such as cellulose, fiberglass, nylon, rayon, brass, aluminum or steel, etc. Dispersed throughout the interfiber voids of the fibrous mass are discrete particles of a nonfilm forming, nonplasticized heat moldable, nontacky resin 11. Preferably these particles are formed of a polyvinyl chloride resin having an average particle size of .2 micron. A range of .01 micron to .55 micron, however, is satisfactory. While the size of these particles within this range is not particularly critical, the particles should not be so small as to readily fall from the mass, nor so large that they would prevent the ready deformation of the mass into a desired form. The resin preferably weighs substantially 50% of the weight of the fibers. However, a range of between 2% and 70% of the total weight of the resin and fibers (or solids) is satisfactory. The fibers and resin particles are compacted so that there is a fiber and resin (or solid) to void ratio of between 1 to 3 and l to 32. Preferably the fiber and resin have a 1 to 16 fiber and resin to void ratio. If desired the fibers may be reinforced with a woven or m atted reinforcing material 12 formed of material such as burlap, cotton cloth, plastic netting, etc.

The voids between the fibers and resin particles and 11 may be filled with air or other displaceable fluid material such as water.

In the formation of the composition illustrated in FIG. 6, a plurality of jute fibers 11, either in the staple or sliver form, are first formed into a mass by suitable and conventional means, by a carding machine or the like, schematically illustrated at 14. The mass of jute fibers is then formed into an integrated partially compact mass wherein the individual fibers tare mechanically locked one to another by suitable needling or gigging means. This interlocking may be accomplished by conventional needle looms schematically illustrated at 15 which pull Itufts of the fibers through the mass to interlock the fibers into a porous mechanically interlocked fibrous mat 16. The mat 16 is then introduced into a resin bath 17 (FIG. 2). This resin bia th preferably comprises an aqueous dispersed solution of nontacky, nonfilm forming, nonplasticized resin particles, preferably polyvinyl chloride particles having a particle size of between .01 micron and .55 micron. The aqueous solution may comprise any volatile fluid which is nonreactive with the resin particles and preferably comprises water. For best results the solid particles should comprise 36% of the total aqueous solution. However, a range of 2% to 60% is satisfactory. After the mat 16 has been immersed in the resin solution 17 a sutficient length of time to permit a thorough dispersion of the resin particles throughout the mat 16, it is withdrawn and squeezed dry by suitable means such as squeeze rollers 18. Following this the partially dried mat may be dried in a hot air drier in which the aqueous solution is volatilized and driven off and the resin. particles are allowed to remain intimately mixed with the fibers. A temperature of 320 to 450 F. has been found satisfactory -for hot air drying. If the fibers are formed of jute the resin particles are dispersed not only throughout the fibrous mass but also within the jute fibers themselves since the jute fibers are normally hollow.

The resin impregnated fibrous composition 20 as thus formed may be molded as illustrated in FIGS. 3, 4 and 5. This composition is particularly useful for molding deepdrawn shapes. The composition is positioned between the male and female halves 21, 22 of a mold without the necessity of trimming, shaping, cutting or shearing the composition. The thickness of the composition 20 is selected so that in its compacted formit will readily fill the closed mold. After positioning the composition 20 between the male and female halves of the mold it is closed as illustrated in FIG. 4 under the influence of pressure supplied from a suitable source such as a hydraulic press. Upon closing the mold the composition 20 is compacted in the contoured or curved portions 25 to a greater degree than in the noncontoured portions 26. As illustrated in FIG. 4 the uncompressed composition 20 may have, for example, a thickness of In the fiat portion of the mold in this example, this thickness may be compressed to of the thickness. In the curved or contoured portion of the mold at 25 the composition 20 is bunched or wrinkled so that there are in fact five plies. These five plies as indicated are each /8 thick. In closing the mold these plies are compressed to a thickness equal to the thickness in the flat portion 26 so that at the corner 25 they are compacted into a much denser composition than at 26. The mold is heated sufiiciently to drive off the displaceable fluids such as water and to cure the resin particles, which under the influence of heat and pressure are compacted into a rigid nondeformable, solid, smooth surfaced end product, as illustrated at 27 in FIG. 5.

While polyvinyl chloride resin particles having a molecular weight of between 60,000 and 150,000 is preferred, other types of resins may be used and substituted in the foregoing examples. Such other resins must be solid at room temperature, must be cured or vulcanized at room temperature or slightly elevated temperatures, must be fused or released from a solution or emulsion on 'heating. If the resin is thermosetting it must be in a non-set condition when mixed with the fibers in order to permit subsequent molding and setting. If the material is filmforming it must be applied in such a manner as not to bind the fibers together prior to molding. This may be accomplished by application of film-forming resins to the fiber with subsequent drying prior to the formation of the interlocked mat. Such resins that may prove suitable include:

Thermoplastic resins Polyvinyl chloride Polypropylene Polystyrene Vinyl-chloride-acetate copolymers Vinylidene chloride-vinyl chloride copolymcr Vinylidene chloride Cellulose triacetate Cellulose acetate butyrate Methyl cellulose Polytri-fiuorochloro-ethylene Vinyl butyral resins Chlorinated polyether Polyethylene Polyvinyl alcohol Cellulose acetate Cellulose nitrate Ethyl cellulose Polyamide (nylon) Polymethyl methacrylate Tetra-fluorocarbon Thermosetting Resins Phenolics Melamine Urea Polyamide epoxy resin Polyesters Diallyl phthalate resin Alkyd resin Elastomers Rubber hydrochloride Acrylonitrile styrene copolymer Vinyl ether resins Vinylidene chloride-acrylonitrile resins Polyether Polyvinyl chloride polymers and copolymers with butadiene acrylonitrile Polyacrylate latices resins Vinyl nitrile rubber Neoprene Vinyl formal resins Silicone resins Urethane Chlorinated rubber Polyvinyl chloride polymers and copolymers with carboxyl modified butacliene acrylonitrile Natural resins Zein Kauri Batu Copal Sandarac Elemi Damar Shellac Mannila Natural waxes Paratfin Microcrystalline waxes Synthetic waxes Polyethylene oxide Chlorinated paraffins Polyethylene glycols Natural gum Locust bean gum Synthetic gum Sodium carboxy methyl cellulose Ethylhydroxyethyl cellulose Hydroxethyl cellulose Methyl cellulose Starch Potato starch Tapioca Etherized potato starch Hydrocarbon resins Turpene resin Coumarone resin and non-contoured portions, said product being derived from a resin impregnated fibrous mass comprising a plurality of fibers formed into a porous mechanically interlocked substantially fiat fibrous mass,

said rigid product containing the molded product of resin material in nontacky, nonfilm fonning, discrete form dispersed substantially uniformly throughout said mass,

said contoured portions of said molded product having a density greater than the density of said non-contoured portions and comprising a plurality of compacted plies of said resin impregnated fibrous mass with said contoured portions and said non-contoured portions having substantially uniform thickness and said contoured portions having a density greater than said non-contoured portions by a factor of at least 3.

2. A molded rigid product in accordance with claim 1 wherein said resin is polyvinyl chloride dispersed throughout said mass and weighing between 2% and of the total weight of said fibers and resin.

3. A molded rigid product in accordance with claim 2 wherein said fibers are jute.

4. A molded rigid product in accordance with claim 1 wherein said fibers are jute.

5. A molded rigid product in accordance with claim 1 wherein said non-contoured portions are flat and have substantially uniform density.

6. A molded rigid product in accordance with claim 5 wherein said contoured portions comprise bent over corners.

References Cited UNITED STATES PATENTS 1,912,931 6/1933 Clay 264324 2,372,433 3/1945 KOOn 161-154 2,373,033 4/1945 Kopplin 161--154 2,773,851 12/1956 Tolman 260-306 1,999,280 4/1935 Cavanagh et a1 161-124 2,797,179 6/1957 Reynolds et a1. 156224 3,121,656 2/1964 Gluck 161-158 MORRIS SUSSMAN, Primary Examiner. 

1. A MOLDED RIGID PRODUCT HAVING CONTOURED PORTIONS AND NON-CONTOURED PORTIONS, SAID PRODUCT BEING DERIVED FROM A RESIN IMPREGNATED FIBROUS MASS COMPRISING A PLURALITY OF FIBERS FORMED INTO A POROUS MECHANICALLY INTERLOCKED SUBSTANTIALLY FLAT FIBROUS MASS, SAID RIGID PRODUCT CONTAINING THE MOLDED PRODUCT OF RESIN MATERIAL IN NONTACKY, NONFILM FORMING, DISCRETE FORM DISPERSED SUBSTANTIALLY UNIFORMLY THROUGHOU SAID MASS, SAID CONTOURED PORTIONS OF SAID MOLDED PRODUCT HAVING A DENSITY GREATER THAN THE DENSITY OF SAID NON-CONTOURED PORTIONS AND COMPRISING A PLURALITY OF COMPACTED PLIES OF SAID RESIN IMPREGNATED FIBROUS MASS WITH SAID CONTOURED PORTIONS AND SAID NON-CONTOURED PORTINS HAVING SUBSTANTIALLY UNIFORM THICKNESS AND SAID CONTOURED PORTIONS HAVING A DENSITY GREATER THAN SAID NON-CONTOURED PORTIONS BY A FACTOR OF AT LEAST
 3. 